Built-in box for supplying internal units of air conditioning systems provided with a condensate collection tray

ABSTRACT

A built-in box for supplying internal units of air conditioning systems includes an essentially parallelepiped-shaped containment body in which there is identified a space delimited by a bottom and by four walls, a tray associable to the bottom of the containment body, for collecting the condensate generated in the internal unit, the tray being laterally provided with at least one discharge duct for discharging the condensate. Inside the tray and in proximity of the discharge duct, there is housed a float which cooperates with the internal walls of the tray for closing the discharge duct at the inlet mouth thereof through a shutter, the float being constituted by a box-shaped element, a laminar wall, rotatably connected to the end part of the tray and stably connected to the box-shaped element, the laminar wall having a gasket suitable to rest against the end part of the tray and close the inlet mouth.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

BACKGROUND OF THE INVENTION 1. The Field of the Invention

The present invention regards a built-in box for supplying internal units of air conditioning systems provided with a new type of condensate collection tray.

2. The Relevant Technology

Use of air conditioning systems in which there are generally identified units inside the building and a unit outside the building are known.

In particular, both in environments inside the building and environments outside the building there are provided wall built-in boxes, where pipes connecting the internal unit to the external unit terminate.

Such boxes are predisposed to receive both the cooling pipes, which go from the external cooling unit to the internal unit for distributing conditioned air and pipes for the electrical wires required for connection between the internal unit and the external unit.

Generally, built-in boxes, during preparation thereof, receive the pipes or ducts that connect the internal unit with the external unit and they are provided with a cover used for concealing such pipes from view.

These built-in boxes are generally parallelepiped-shaped and they are provided with pre-breakable areas for the entry of gas pipes or electrical wires coming from one of the internal units.

Built-in boxes having a condensate collection tray so that, when the unit is operating as a cooling unit, the condensate that is created is discharged onto the tray, which is provided with at least one discharge duct that discharges the condensate towards the external, have become more and more common recently.

Trays having two or more discharge ducts, arranged in one of the lateral walls of the tray have become increasingly common of late.

However, built-in boxes of the known type reveal some drawbacks.

Actually, the collection trays contain a considerable amount of condensate especially in summer, when the internal unit is frequently used for generating conditioned air.

Due to various technical needs, the condensate discharge pipes of the internal unit are often connected with systems for discharging sewage and waste water (e.g., Kitchen, bathroom, toilet). In summer, the operation of the internal unit creates a considerable condensate water flow which flows towards the discharge systems carrying impurities (dust, insects) and foul odour.

The level of condensate generated inside the tray remains high as long as the air conditioning system is used frequently; on the other hand, the condensate level drops when the conditioning system is not used and this occurs especially during cold periods when the disuse of the air conditioning system progressively lets the level of the condensate that deposits in the pipes to evaporate (e.g., shower siphons dry during summer with ensuing foul odour).

As the level of the condensate drops progressively, the barrier it creates against entry of foul odour becomes progressively weaker, thus allowing penetration thereof from the external environment to the internal environment through the discharge duct.

Built-in boxes equipped with a condensate collection tray in which there is obtained a siphon suitable to contain the condensate have been provided with the aim of overcoming the aforementioned drawback.

However, even in this type of solution the condensate contained in the tray is subjected to evaporation during periods in which the air conditioning system is not used, thus letting foul odour and dirt (dust, insects) to penetrate from the external.

The present invention has the object of overcoming these drawbacks.

In particular, an object of the present invention is to provide a built-in box provided with a condensate collection tray configured so as to avoid the entry of foul odour and dirt from the external even if the system is not used for long periods.

A further object of the present invention is to provide a built-in box provided with a condensate collection tray capable of preventing the entry of dirt and foul odour from the external without interfering with the pipes and/or electrical wires that terminate in the built-in box.

The aforementioned objects are attained by the present invention regarding a built-in box whose main characteristics are outlined in the main claim.

Further characteristics of the invention are outlined in the dependent claims.

Advantageously, the built-in box according to the invention is provided with a float provided with means for shutting the discharge pipe, the float being suitable to take two different positions depending on the presence or absence of the fluid in the tray.

Still advantageously, the float of the built-in box according to the invention rotates around a rotational axis and it is pushed from the bottom upwards by the underlying condensate according to Archimedes' principle.

Still advantageously, the float of the built-in box according to the invention comprises a gasket which ensures that the discharge duct is always closed and no dirt and foul odour enters from the external when the condensate level drops.

Still advantageously, the float of the built-in box according to the invention is easily applicable to built-in boxes of the known type.

BRIEF DESCRIPTION OF THE DRAWINGS

The aforementioned objects and advantages shall be more apparent from the description of a preferred embodiment of the invention, outlined hereinafter by way of non-limiting example, with reference to the attached drawings, wherein:

FIG. 1 represents an exploded axonometric view of a built-in box according to the invention provided with a condensate collection tray equipped with a float;

FIG. 1a represents a partial axonometric view of a detail of FIG. 1 with the float of the invention highlighted;

FIG. 2 represents an axonometric view of FIG. 1 assembled;

FIG. 3 represents an enlarged axonometric view of the float present in the tray of FIG. 1;

FIG. 4 is a partially cut away perspective view of the assembled condensate collection tray and float shown in FIG. 2;

FIG. 5 is a partial cross sectional side view of the condensate collection tray and float shown in FIG. 4;

FIG. 6 is a partial cross sectional side view of the condensate collection tray and float of FIG. 5 shown in use;

FIG. 7 is a perspective view of the condensate collection try and float with a shaped plate exploded therefrom; and

FIG. 8 is a perspective view of the condensate collection tray and float of FIG. 7 with the shaped plate attached thereto.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIGS. 1, 1 a and 2, they show a built-in box, indicated in its entirety with 1, for supplying the internal units of air conditioning systems.

The built-in box 1 comprises:

a substantially parallelepiped-shaped containment body 2 in which there is identified a space delimited by an open bottom 3 and four walls, respectively 4 a, 4 b, 4 c, 4 d;

a condensate collection tray 5, associable to the open bottom 3 of the containment body 2 and laterally provided with a discharge duct 6 for discharging the condensate C.

It should be observed that the tray 5 may be positioned with the discharge duct on the left as represented, or on the right depending on the installation needs.

Electrical wires as well as inlet and outlet pipes (not shown in the figures) of the air conditioning system pass through the containment body 2.

In particular, in the four walls, respectively 4 a, 4 b, 4 c, 4 d, there is identified an upper wall 4 a, two lateral walls 4 b, 4 c and a rear wall 4 d, while the bottom 3 is open in a manner such to associate the tray 5 to the containment body 2.

The upper wall 4 a, the lateral walls 4 b and 4 c, as well as the rear wall 4 d have predefined fracture areas suitable to open windows to be broken for the entry and exit of the pipes of the air conditioning system cooling lines (not represented).

Said areas are indicated with reference number 40.

Obviously, the opening of these breaking areas depends on the entry and exit position of the pipes for the air conditioning system cooling lines.

As concerns the passage of the electrical wire, it is provided in the predefined fracture area indicated with 41.

On the bottom wall 4 d, as shown in FIGS. 1 and 2, there can be applied a bubble level gauge 42 which is particularly useful for the horizontal positioning of the built-in box 1.

It should be observed that in the embodiment illustrated herein there is only one discharge duct; however, in a variant embodiment (not illustrated in the figures) there can be provided two discharge ducts, one for each lateral wall 7 a, 7 b of the tray 5.

Furthermore, the discharge duct 6, represented horizontal in FIGS. 1 and 2, may also be arranged vertically downwards, depending on the needs.

According to the present invention and as observable in FIGS. 1, 1 a and 2, inside the tray 5 and in proximity of the discharge duct 6 there is housed a float indicated in its entirety with 8.

The float 8 cooperates with the tray 5 to close the discharge duct 6, the closing being carried out by shutter means to be described hereinafter and which are constrained to the float 8, just like the shutting of the discharge duct 6 occurs at the inlet mouth 11 thereof.

More particularly, the tray 5, at the final part 7 a thereof where the inlet mouth 11 of the discharge duct 6 is present, has a recessed part 5 a where the float 8 is housed.

The float 8, as observable in FIG. 3, is formed by a box-shaped element 12 open at the top and having a bottom 12 a which rests in proximity of the bottom of the recessed part 5 a, when there is no condensate water in the tray.

Said box-shaped element 12 is connected to a laminar wall 13 by means of a vertical strip 14.

The laminar wall 13 ends—at the top part—with a tubular rod 15 with projecting ends with respect to the width of the laminar wall 13 and with axis X lying on the same plane as said laminar wall 13.

In a preferred embodiment of the invention, the float 8, i.e., the components thereof constituted by the box-shaped element 12, the vertical strip 14, the laminar wall 13 and the tubular rod 15, are made in a single piece by moulding plastic material for example PVC, nylon, ABS.

It should be observed that the vertical strip 14 is essentially perpendicular both to the laminar wall 13 and to a surface of the box-shaped element 12.

At the inlet mouth 11 of the discharge duct 6 there is a gasket 19 fixed to the laminar wall 13.

Such gasket, preferably but not necessarily circular, rests on the wall 7 a of the tray 5 and perfectly closes the hole of the discharge duct 6 when the box-shaped element 12 rests in proximity of the bottom of the recessed wall 5 a of the tray 5, or in proximity thereto as observable in FIG. 4.

In fact, the tubular rod 15 which rests the projecting elements thereof on cavities 16 present on the tray 5 (see FIG. 7), enables, in absence of condensate water, the rotation of the float 8 around the axis thereof X and towards the mouth 11 of the discharge hole 6.

This enables closing the hole of the discharge duct.

In this condition, the gasket 19, fixed to the laminar wall 13 rests against the wall 7 a of the tray 5 with a thrust generated by a rotational torque corresponding to the weight of the box-shaped element 12 for the length l of the vertical strip 14 (see FIG. 5).

On the contrary, when there is condensate on the bottom 5 a of the tray 5, the latter, due to the hydraulic thrust exerted on the bottom 12 a of the box-shaped element 12, generates an upward thrust which rotates the float 8 around the axis X of the tubular rod 15 so that the gasket 19 moves away from the wall 7 a and the condensate may be discharged into the discharge duct 6.

It should be observed that the float 8 has the box-shaped element 12 whose distance from the laminar wall 13 is equivalent to the length 1 of the vertical strip 14; this enables maximising the hydraulic thrust that the bottom 12 a of the box-shaped element 12 receives in presence of water due to the lever effect that is generated.

Thus, the discharge duct opens and the condensate may flow out.

Likewise, when there is no condensate water, the weight force of the box-shaped element 12 transmits to the laminar wall 13 a thrust corresponding to the moment produced by the weight force of the box-shaped element multiplied by the distance between the barycentre of said box-shaped element 12 and the laminar wall 13 that lies on the rotational plane of the pin 15.

This enables ensuring the hermetic sealing given that the gasket 19 pushes against the hole 11 of the discharge duct 6.

Thus, it is clear that the geometry of the float 8 according to the invention is efficient both for closing and opening the discharge hole also in conditions in which in the tray 5 there could be present impurities that could be interposed between the gasket 19 and the discharge hole 6.

This due to the fact that the closing force exerted by the gasket 19 is increased by the lever arm represented by the length l of the vertical strip 14 (see FIG. 5).

As observable in FIGS. 7 and 8, a shaped plate 22 is also connected to the tray 5.

In particular, the shaped plate 22 is placed over the upper perimeter edge 10, as observable in FIG. 7, and it comprises a flat surface 23 and a retention element 24 orthogonal to the flat surface 23 having a plurality of flat fins 27.

Still observing FIG. 7, the shaped plate 22 is provided with through holes 25, which receive—in closure—the pins 26 projecting from the perimeter edge 10 of the tray 5.

Basically, as observable in FIG. 8, the shaped plate 22 is pressure-inserted onto the pins 26 enabling a stable coupling therewith.

Advantageously, the shaped plate 22 performs three functions: the first is that of preventing the inadvertent disengagement of the float 8 from the seat thereof, and i.e., the disengagement from the recesses 16; the second is that of preventing the electrical wires and pipes passing into the containment body 2 of the built-in box 1 from interfering with the float 8 upon lowering; the third is that of withholding the dirt that may find its way into the tray 5 and jeopardising the correct operation of the float 8.

Operatively and with reference to FIGS. 5 and 6, the float 8 operates as follows.

When there is no condensate water in the tray 5, the situation is the one represented in FIG. 5, where the float 8 rests with the base 12 thereof in proximity with the bottom 5 a of the tray 5; thus, the inlet mouth 11 of the discharge duct 6 is closed by a gasket 19.

This enables preventing the exit of foul odour that could also come from other pipes connected to the same discharge, for example from kitchen or bathroom pipes.

On the contrary, when the condensate C forms, following the use of the air conditioning system, the fluid present on the tray pushes the float 8 upwards, as observable in FIG. 6.

Thus, rotating the wall 7 a and the gasket 19, enables reopening the inlet mouth 11 of the discharge duct 6 and the condensate C flows out.

Basically, the float 8 operates according to Archimedes' principle, according to which a body (the float 8 in this case) submerged in a fluid (the condensate C in this case) receives an upward thrust equivalent to the weight of the volume of the displaced fluid.

Thus, as the condensate C progressively deposits on the bottom 18 of the tray 5, the float 8 rotates upwards around the axis X, which represents both the rotational axis of the float 8 and the longitudinal axis of the tubular element 15.

While the float 8 rotates upwards, the gasket 19 is decoupled from the inlet mouth 11 of the discharge duct 6, so as to flow the condensate C towards the external.

Lastly, it should be observed that, in the particular embodiment of the invention shown in the example of FIGS. 1 and 2, the built-in box of the invention is provided with a pair of front fins 9 arranged at the lateral walls 4 b and 4 c which serve to facilitate the blocking of the built-in box 1 on the wall (not represented).

For each fin, there are provided slots 9 a and 9 b for housing means, like screws or the like, for fixing to the wall which supports the built-in box and the wall can also be made of wood in houses made of this material.

Should the fins 9 not be required in that the box 1 is housed in a previously provided wall recess, such fins may be easily removed by the installation technician in that, in proximity of the coupling of said fins with the containment body 2, there are provided pre-fracture lines 9 c.

Actually, in such case it is sufficient to bend the fins with pliers to obtain the desired detachment.

In the light of the above, the built-in box according to the invention attained the pre-set objects.

In particular, the object of preventing the penetration of dirt and foul odour into the tray from the external due to a built-in box provided with a tray equipped with a float which provides for closing the discharge duct or ducts of the tray, is attained. When the air conditioning system does not generate condensate, this is an important factor in that foul odour is smelt by the people even externally.

In addition, the object of preventing penetration of dirt and foul odour from the external by simply introducing a float into the condensate collecting tray, in proximity of the discharge duct, without interfering with the pipes and/or electrical wires that terminate in the built-in box, has been attained.

Advantageously, the aforementioned float may take various configurations and adapt to trays of different types and with different inclination.

In the executive step, the built-in box according to the invention may be subjected to modifications and variants not described and represented in the figures herein, all of which shall be deemed protected by the present patent should they fall within the scope of protection of the claims that follow. 

What is claimed is:
 1. A built-in box for supplying internal units of air conditioning systems comprising: an essentially parallelepiped-shaped containment body in which there is identified a space delimited by a bottom and by four walls; a tray associable to the bottom of said containment body, for collecting the condensate generated in the internal unit, said tray being laterally provided with at least one discharge duct for discharging the condensate wherein, inside said tray and in proximity of at least one discharge duct, there is housed a float which cooperates with the internal walls of said tray for closing said at least one discharge duct at the inlet mouth thereof through shutter means, said float being constituted by a box-shaped element, a laminar wall, rotatably connected to the end part of the tray and stably connected to said box-shaped element, said laminar wall having a gasket suitable to rest against the end part of the tray and close the inlet mouth of the discharge duct.
 2. The built-in box according to claim 1, wherein the laminar wall has, at the top part, a tubular rod having ends projecting with respect to said laminar wall, the axis (X) of said tubular rod being rotational axis of said float.
 3. The built-in box according to claim 1, wherein the box-shaped element and said laminar wall are connected to each other through a vertical strip essentially perpendicular to a surface of said box-shaped element and said laminar wall.
 4. The built-in box according to claim 1, wherein the box-shaped element, said vertical strip and said laminar wall are made in a single piece made of plastic material.
 5. The built-in box according to claim 1, wherein the box-shaped element is open towards the top and it has a bottom which receives a hydraulic thrust in presence of water condensate such to rotate said float around the axis (X) of the tubular rod so as to move said gasket away from the wall of said tray.
 6. The built-in box according to claim 1, wherein the containment body has predefined fracture areas in the upper wall, in the lateral walls and in the rear wall, so as to enable, when open, the entry and exit of pipes for cooling the air conditioning system.
 7. The built-in box according to claim 1, wherein it further has a shaped plate placed above the upper perimeter edge of said tray, such to separate the space in which said float acts, from the containment body of the built-in box, said shaped plate having a flat surface and a plurality of flat fins arranged inside said tray, said fins being substantially perpendicular to said flat surface.
 8. The built-in box according to claim 1, wherein it has a pair of front fins arranged at the lateral walls of said containment body, said front fins having slots suitable to house means for fixing to the wall that support said built-in box.
 9. The built-in box according to claim 8, the front fins have, at the coupling with the containment body, pre-fracture lines such to enable detachment from said containment body if necessary.
 10. The built-in box according to claim 1, further comprising, at the rear wall of said containment body, a bubble level gauge suitable to indicate the horizontal position of said built-in box. 